Apparatus for forming a pattern on the surface of a moldable material

ABSTRACT

An apparatus for forming a pattern on the surface of a moldable material such as concrete including a frame having patternforming means mounted thereon and adapted to extend across a mold. The pattern-forming means is movable relatively to the frame and the frame is movable relatively to the mold so that, in use, the two movements cause a pattern to be formed on the surface of the material in the mold.

United States Patent Newby 5] Aug. 19, 1975 [54] APPARATUS FOR FORMING A PATTERN 1,720,377 7/1929 Pope 404/1 16 ON THE SURFACE OF A MOLDABLE Ef i 281;} e 1.26 i MATERIAL 2,582,486 1/1952 Jackson 404/116 [75] Inventor; Ronald Newby, Borehamwood, 3,516,340 6/1970 Perkins.... 404/75 England 3,604,325 9/1971 Borges 404/120 [73] Assignee: John Laing and Son Limited,

London, England Primary Examiner-Robert D. Baldwin [22] Filed: 6' 1973 Assistant Examiner.lohn McQuade Attorney, Agent, or Firm-Kenyon & Kenyon Reilly [21] Appl. No.: 413,220 Carr & Chapin Related US. Application Data [63] Continuation-in-part of Ser. No. 155,810, June 23,

1971, abandoned, [57] ABSTRACT [30] Forelgn Apphc au0n Pn0nty Data An apparatus for forming a pattern on the surface of a June 30, 1970 United Kingdom 31486/70 moldable material Such as Concrete including a frame having pattern-forming means mounted thereon and 52 US. Cl 425/385; 425/457 adapted to extend across a mold The pattemforming [5 l] [131. CL... B281) 11/08 means is movable relatively to the frame and the [58] Fleld of search 264/1 162; 425/62 frame is movable relatively to the mold so that, in use, 425/299, 304, 356, 385, 457; 404/75, 93- the two movements cause a pattern to be formed on 1 1 1 18*120 the surface of the material in the mold.

[561 References Cited 11 C1 10 D F UNITED STATES PATENTS rawmg 1,234,098 7/1917 Koch 425/385 9 mm mm 9 m5 SEEP BF 5 I Ill. IDDU INVENTOR B RONALD NEWBY ATTORNEYj APPARATUS FOR FORMING A PATTERN ON THE SURFACE OF A MOLDABLE MATERIAL This application is a continuation-in-part of copending application Ser. No. 155,810, filed June 23, 1971 now abandoned.

The present invention relates to apparatus for forming a pattern on the surface of a moldable material, and is directed more particularly, although not exclusively, to the formation of a pattern on water hardenable material such as concrete.

I-Ieretofore, the forming of a pattern on the surface of concrete immediately after casting has been effected manually by the use of pattern formers or other hand tools, both of which methods are relatively costly and time-consuming.

An object of the present invention is to provide an apparatus for forming a pattern on the surface of a moldable material which overcomes the disadvantages referred to above and also enables wide variety of patterns to be readily reproduced when required.

A further object is to provide a mold having flexible end Walls which enable the pattern to be formed over the entire length of the moldable material.

The present invention consists in apparatus for form ing a pattern on the surface of a moldable material comprising, a frame adapted to extend across a mold, pattern-forming means mounted on said frame, means for moving said pattern-forming means relative to the frame and means for effecting relative movement between the frame and the mold so that, in use, said movements cause a pattern to be formed on the surface of the material in the mold.

In one embodiment, the pattern-forming means is mounted on a pair of pivotally mounted arms and is pivoted in synchronism with the movement of the apparatus along a mold.

In another embodiment, the pattern-forming means is selectively actuated via a clutch mechanism, or other suitable mechanism, to move in synchronism with the movement of the apparatus relative to the mold. In this embodiment, during certain times, the pattern-forming means can be fixed in one position and, during other times, can be moved in synchronism with the apparatus.

In the accompanying drawings:

FIG. 1 is a front elevation of an apparatus according to the present invention for forming a pattern on the surface of a moldable material;

FIG. 2 is a side elevation of the apparatus shown in FIG. 1;

FIG. 3 is a cross-sectional view taken on line 33 of FIG. 1;

FIG. 4 is a cross-sectional view taken on line 44 of FIG. 3;

FIG. 5 is a rear elevation of a portion of a modified apparatus, similar to that shown in FIG. 1;

FIG. 6 is a plan view of FIG. 5;

FIG. 7 is a fragmentary side elevation of the apparatus shown in FIG. 5;

FIG. 8 illustrates a top view of another embodiment of an apparatus according to the invention;

FIG. 9 illustrates a front elevation of the apparatus of FIG. 8; and

FIG. 10 illustrates a view taken on line 10-10 of FIG. 8.

In carrying the invention into effect according to one convenient mode, by way of example, the apparatus comprises, basically, a self-propelled trolley or frame 10 supported on guide rails 11 positioned above and parallel to the surface of the mold 12, accommodating the concrete to be patterned, with a blade 13 or other pattern forming member extending transversely of the mold 12. The end walls of the mold are formed from polyurethane foam material.

The trolley 10 comprises frame members 14 extending between spaced side plates 15, 16 with wheels 17 mounted on the extremities of the upper frame members 14 to support the trolley 10 on the guide rails 11 which extend longitudinally of the mold 12.

A prime mover 18 mounted on the trolley has a sprocket 19 on its power output shaft drivingly connected through a chain 20 with a further sprocket 21 fixedly mounted on the drive input shaft 22 of a gearbox or reduction gearing 23. The output shaft 24 of the gearbox is drivingly connected through a sprocket 25 and chain 26 to a further sprocket 27 fixedly mounted on a power take-off shaft 29 which is rotatably mounted in spaced plates 30, 31 with its axis parallel to the frame members 14. A trolley drive sprocket 32, mounted on the power take-off shaft 29 and positioned between the plates 30, 31, engages with a chain 33 (see FIG. 2) positioned centrally of and longitudinally of the trolley 10, so that rotation of the drive sprocket 32 causes the trolley 10 to propel itself along the chain 33. The latter passes over the drive sprocket 32 and is held in engagement therewith by passing under spaced guide sprockets 34 positioned, respectively, fore and aft of the drive sprocket 32.

Normally, the weight of the trolley 10 is sufficient to maintain the wheels 17 in contact with the guide rails 11, but if for any reason the trolley during operation tends to rise, a reaction wheel 35 may be provided on each side thereof which engages the underside of a reaction rail 36 extending beneath and parallel to the guide rail 11.

The blade 13 profiled to produce the required pattern on the surface of the concrete in the mold 12 extends transversely of the trollle y 10, i.e. parallel to the frame members 14, 15 adjustably mounted by means of bolts 37a on a beam 37 extending between the extremities of radius arms or links 38 which are also interconnected by a cross-member 39 and supported on the side plates 15, 16 by means of pivot bearings 40 each of which is positioned above and behind the blade 13 rela tive to its direction of travel. Thus, the profiled blade is mounted for arcuate movement about the pivots 40 of the radius arms 38.

The profiled blade 13 is driven off the prime mover 18 via a suitable drive means in order to be operated in synchronism with the movement of the trolley 10. This means includes a cam 41 fixedly mounted on the output shaft of the prime mover 18, one roller 42, a pushrod 43 and a link 44. The profiled surface of the cam 41 engages the roller 42 which is rotatably mounted in the upper end of the pushrod 43, the lower end of which comprises the link 44 which is connected to the cross-member 39 by means of a pin passing through spaced ears 45 mounted on the cross-member. A screwed member 46 permits adjustment of the effective length ofthe pushrod in known manner and a locknut 47 maintains the required length thereof. Thus it will be seen that rotation of the cam 41 effects the arcuate movement of the blade 13.

A spring 48 is positioned between each radius arm 38 and an associated frame bracket 49 urges the crossmember 39 upwardly so that the roller 42 is maintained in contact with the cam 41. A screwed member 50 permits adjustment of the tension of each spring 48 and a lock-nut 51 maintains the required tension.

The pushrod 43 is mounted for reciprocal movement in a guide member 52 (see FIG. 4) integral with a pivot pin 53 which is journalled for rotative movement in a block 54. The block 54 is positioned between aligned slots 55, 56 formed, respectively, in the plates 30, 31, and is guided for movement therein by flanges 54a. A lever 76 is mounted intermediate its end on a pivot pin 77 and the end of the lever positioned adjacent the block 54 is provided with an upstanding catch member 78 which engages a downwardly depending abutment 79 (see FIG. 4) on the block 54. A tension spring 57, positioned between the block 54 and the plates 30, 31 urges the block 54 towards the right as viewed in FIG. 3, but is prevented from so doing during operation of the apparatus by the engagement of the catch member 78 with the abutment 79.

At the end of a pattern-forming operation, upward movement of the end of the lever remote from the catch member 78 releases the latter from the abutment 79 and the spring 57 moves the block 54 to the right as viewed in FIG. 3. Thus it will be seen that this arrangement permits the pushrod 43 to be removed from engagement with the cam 41 at the end of a patternforming operation, whatever the position of the cam.

In operation, rotation of the power output shaft 29 by the prime mover 18 causes the trolley 10 to be propelled along the guide rails 11 at a constant speed whilst, simultaneously, the blade 13 is moved through an arc about the pivots 40 at a speed which is relative to the trolley speed. The movement of the blade 13 relative to the surface of the concrete mix in the mold is dependent on the profile of the cam 41 and, during a downward movement through the arc, could be reverse to the direction of travel of the trolley.

Thus, by varying the profile of the blade 13, and/or the profile of the cam 14, and/or the speed of the trolley 10, a wide range of patterned finishes can be produced.

In a modified form of the invention shown in FIGS. to 7, now to be described and in which like reference numerals indicate parts which are the same as those in FIGS. 1 to 4, the blade 13 is mounted for transverse, movement relative to the trolley in order to produce an even wider range of patterned surfaces. If it is desired to produce a pattern only by the transverse movement, the pushrod 43 of FIGS. 1 to 4 is removed from engagement with its cam 41.

The modified trolley shown in FIGS. 5 to 7 is similar to that shown in FIGS. 1 to 4 except that in the modified construction the cross-member 39 is of square cross-section and the blade 13 and its associated beam 37 is slidably mounted therein. In order to effect the blade movement, the power take-off shaft 29 is provided with a sprocket 60 which transmits the drive through a sprocket chain 61 and further sprocket 62 to a variable ratio gearbox 63 mounted on one of the upper frame members 14.

The drive is transmitted to bevel gearing 64 housed in a casing 65 mounted on the forward end of one of the radius arms 38 through a drive shaft 66 and universal joints 67. The bevel gearing drives a cam 68 which engages a roller 69 rotatably mounted in the end of a rod 70 which is slidably mounted in a guide 71 attached to the underside of the casing 65. The beam 37 is connected to the rod 70 by means of ball joints 72 and a pushrod 73. The beam 37 is provided with a plurality of spaced brackets 74 which are slidably mounted on the cross-member 39. An adjustable spring 75 urges the beam 37 and associated blade 13 towards the radius arm 38 on which the bevel gearing casing 65 is mounted so that the roller 69 is always maintained in contact with the cam 68.

Thus, it will be seen that the transverse movement of the blade 13 is related to the distance travelled by the trolley and this movement can be varied by means of the variable ratio gearbox 63. Furthermore, in both constructions described above, the relative movement between the trolley and the mold may, if desired, be effected by mounting the mold on rollers and guide rails to obtain longitudinal movement relative to the profiled blade. It will also be appreciated that the pattern forming means may take a wide variety of forms, for example, a rod having members of various shapes mounted at various angles positioned along the length of the rod.

It is to be noted that patterns may be formed by a combination of the trolley movement and arcuate blade movement as described with reference to FIGS. 1 to 4, or a combination of the trolley movement and horizontal blade movement as described with reference to FIGS. 5 to 7, or a combination of the trolley movement and arcuate and horizontal blade movements.

Referring to FIGS. 8 to 10, wherein like reference characters indicate like parts as described above, instead of driving the blade 13 directly off the prime mover 18, the blade 13 can be selectively actuated. To this end, the power output shaft of the prime mover operates a drive means which includes a cam 81 which is engageable with the output shaft 80 and which has a profiled surface in engagement with a roller 82 rotatably mounted on the upper end of a rocker arm 83. This rocker arm 83 is, in turn, pivoted at an intermediate point of the trolley frame 10. The lower end of the rocker arm 83 is pivotally connected to a link 84 rigidly fixed to a beam 85 interconnected in pivotal relation between and to a pair of arms 86. The upper ends of the arms 86 are pivotally and adjustably mounted on the side plates 15, 16 via pivot pins 87. As shown, the side plates 15, 16 have a series of slots 88 to receive the pins 87 in order to adjust the pivot axis of each arm 86. Each arm 86 is positioned above and behind the blade 13 relative to the direction of travel of the apparatus. In this way, the profiled blade 13 is mounted for arcuate movement about the upper pivots of the arms 86.

The rocker arm 83 is biased by a suitable means (not shown) so that the roller 82 is biased into contact with the cam 81. Thus, upon rotation of the cam 81, in addition to the arcuate movement about the upper pivots of the arms 86, the cam 81 effects a pivotal movement of the blade 13 and beam 85 about the arms 86.

The cam 81 is engaged or disengaged from the power output shaft 80 of the prime mover 18 by means of a clutch 89, the actuating linkage of which extends transversely of the apparatus and terminates in a clutch operating lever 90 pivotally mounted on one side of the apparatus. As shown, the actuating linkage includes a horizontal shaft 91 which is slidably mounted in an upstanding bracket 92 fixed to the apparatus frame. This shaft 91 is coupled at one end. via a coupling93, to the lever 90 and at the other end the cam 81 is rotatably mounted thereon. The lever 90 can be actuated manually to engage or disengage the'cam 81 and output shaft 80 in order to vary the pattern being formed on the concrete in the mold 12. i

It is to be appreciated that the pivotal movement of the blade 13 relative to the arms 86 may be effected by a Bowden cable control or any other suitable means.

In operation, with the cam 81 engaged with the power shaft 80, rotation of the power output shaft 80 by the prime mover 18 causes the trolley to be propelled along the guide rails 11 at a constant speed. At the same time, the blade 13 is moved via the rocker arm 83 through an arc about the pivots of the 86 and is pivoted about the arms 86 at a speed which is relative to the trolley speed. This oscillation of the pattern-forming blade 13 by the drive means allows a more complex motion to be imparted to the blade 13 than a simple up and down type of motion. Further, by varying the profile of the blade 13 and/or the profile of the cam 81 and/or the speed of the trolley, a wide range of patterned finishes can be produced.

The invention thus provides an apparatus which can be moved relative to a mold while a drive means for moving a pattern-forming blade is operated in synchronism with the movement of the apparatus. The drive means can either be directly connected to the prime mover of the apparatus or indirectly connected via a clutch. ln this latter case, the movement of the patternforming blade can be stopped while the apparatus is moved relative to the mold.

What is claimed is:

1. Apparatus for forming a pattern on the surface of a moldable material comprising a frame adapted to extend across a mold;

spaced pivotally mounted arms on said frame;

a pattern-forming means mounted on and between said arms to extend across the mold;

drive means for pivoting said arms relative to said frame to move said pattern-forming means arcuately relative to the frame; and

means for effecting relative movement between said frame and the mold, said latter means including a prime mover with said drive means being connected to said prime mover to be driven in synchronism with said means for effecting relative move ment, whereby during use said movements of said frame and said arms cause a predetermined repetitive pattern to be formed on the surface of the material in the mold.

2. Apparatus as set forth in claim 1 which further includes a clutch for selectively connecting said drive means to said prime mover.

3. Apparatus as set forth in claim 1 wherein said drive means includes a cam driven by a prime mover which engages a pushrod connected to said pattern forming means.

4. Apparatus as claimed in claim 3 wherein the push rod is maintained in contact with said cam by spring means.

5. Apparatus as claimed in claim 4 wherein the frame is provided with wheels which. in use, are supported on guide rails extending along opposite sides of the mold, said drive means being also operatively connected to a ,drive sprocket which engages a chain positioned parallel to the guide rails, the arrangement being such that rotation of the drive sprocket causes the apparatus to propel itself along the chain.

6. Apparatus as claimed in claim 1 wherein said pattern-forming means are mounted for transverse movement relative to the frame.

7. Apparatus as claimed in claim 6 wherein a beam is mounted across said frame: and said pattern-forming means is adjustably mounted on said beam, said transverse movement being effected by a cam driven by a prime mover which engages a pushrod connected to said pattern-forming means.

8. Apparatus for forming a pattern on a surface of a moldable material comprising a frame adapted to extend across a mold; spaced pivotally mounted arms on said frame; a pattern-forming means pivotally mounted on and between said arms to extend across said mold;

drive means pivotally connected to said patternforming means for pivoting said arms relative to said frame and said patternforming means in said arms to move said pattern-forming means relative to said frame; and

means for effecting relative movement between said frame and the mold, said latter means including a prime mover with said drive means being connected to said prime mover to be driven in synchronism with said means for effecting relative movement, whereby during use said movement of.said frame and said pivotal movement of said arms and pattern-forming means cause a predetermined repetitive pattern to be formed on the surface of the material in the mold.

9. Apparatus for forming a pattern on a surface of a moldable material comprising a frame adapted to extend across a mold;

spaced pivotally mounted arms on said frame;

a prime mover for effecting relative movement between said frame and the mold; a pattern-forming means pivotally mounted on and between said arms to extend across said mold; and

drive means pivotally connected to said patternforming means for pivoting said arm relative to said frame and said pattern-forming means in said arms to move said pattern-forming means relative to said frame, said drive means including a cam engageable with said prime mover, a rocker arm pivotally mounted on said frame and biased into contact at one end with saidcam and a link pivotally connected to an opposite end of said rocker arm and fixedly connected to said pattern-forming means; said drive means and said prime mover being operated in synchronism whereby during use said rela' tive movement between the frame and the mold and the pivotal movement of said arms and patternforming means cause a predetermined repetitive pattern to be formed on the surface of the material in the mold.

10. Apparatus as set forth in claim 9 which further comprises a clutch for selectively connecting said cam with said prime mover.

11. Apparatus for forming a pattern on the surface of a moldable material comprising a frame adapted to extend across a mold;

spaced pivotally mounted arms on said frame;

means for effecting relative movement between said frame and the mold. said drive means and said means for effecting relative movement being operated in synchronism whereby during use said movements of said frames and said arms cause a predetermined repetitive pattern to be formed on the surface of the material and the mold.

l l =l 

1. Apparatus for forming a pattern on the surface of a moldable material comprising a frame adapted to extend across a mold; spaced pivotally mounted arms on said frame; a pattern-forming means mounted on and between said arms to extend across the mold; drive means for pivoting said arms relative to said frame to move said pattern-forming means arcuately relative to the frame; and means for effecting relative movement between said frame and the mold, said latter means including a prime mover with said drive means being connected to said prime mover to be driven in synchronism with said means for effecting relative movement, whereby during use said movements of said frame and said arms cause a predetermined repetitive pattern to be formed on the surface of the material in the mold.
 2. Apparatus as set forth in claim 1 which further includes a clutch for selectively connecting said drive means to said prime mover.
 3. Apparatus as set forth in claim 1 wherein said drive means includes a cam driven by a prime mover which engages a pushrod connected to said pattern forming means.
 4. Apparatus as claimed in claim 3 wherein the pushrod is maintained in contact with said cam by spring means.
 5. Apparatus as claimed in claim 4 wherein the frame is provided with wheels which, in use, are supported on guide rails extending along opposite sides of the mold, said drive means being also operatively connected to a drive sprocket which engages a chain positioned parallel to the guide rails, the arrangement being such that rotation of the drive sprocket causes the apparatus to propel itself along the chain.
 6. Apparatus as claimed in claim 1 wherein said pattern-forming means are mounted for transverse movement relative to the frame.
 7. Apparatus as claimed in claim 6 wherein a beam is mounted across said frame and said pattern-forming means is adjustably mounted on said beam, said transverse movement being effected by a cam driven by a prime mover which engages a pushrod connected to said pattern-forming means.
 8. Apparatus for forming a pattern on a surface of a moldable material comprising a frame adapted to extend across a mold; spaced pivotally mounted arms on said frame; a pattern-forming means pivotally mounted on and between said arms to extend across said mold; drive means pivotally connected to said pattern-forming means for pivoting said arms relative to said frame and said pattern-forming means in said arms to move said pattern-forming means relative to said frame; and means for effecting relative movement between said frame and the mold, said latter means including a prime mover with said drive means being connected to said prime mover to be driven in synchronism with said means for effecting relative movement, whereby during use said movement of said frame and said pivotal movement of said arms and pattern-forming means cause a predetermined repetitive pattern to be formed on the surface of the material in the mold.
 9. Apparatus for forming a pattern on a surface of a moldable material comprising a frame adapted to extend across a mold; spaced pivotally mounted arms on said frame; a prime mover for effecting relative movement between said frame and the mold; a pattern-forming means pivotally mounted on and between said arms to extend across said mold; and drive means pivotally connected to said pattern-forming means for pivoting said arm relative to said frame and said pattern-forming means in said arms to move said pattern-forming means relative to said frame, said drive means including a cam engageable with said prime mover, a rocker arm pivotally mounted on said frame and biased into contact at one end with said cam and a link pivotally Connected to an opposite end of said rocker arm and fixedly connected to said pattern-forming means; said drive means and said prime mover being operated in synchronism whereby during use said relative movement between the frame and the mold and the pivotal movement of said arms and pattern-forming means cause a predetermined repetitive pattern to be formed on the surface of the material in the mold.
 10. Apparatus as set forth in claim 9 which further comprises a clutch for selectively connecting said cam with said prime mover.
 11. Apparatus for forming a pattern on the surface of a moldable material comprising a frame adapted to extend across a mold; spaced pivotally mounted arms on said frame; a pattern-forming means mounted on and between said arms to extend across the mold; drive means for pivoting said arms relative to said frame to move said pattern-forming means arcuately relative to said frame, said drive means including a cam driven by a prime mover which engages a push rod connected to said pattern forming means; and means for effecting relative movement between said frame and the mold, said drive means and said means for effecting relative movement being operated in synchronism whereby during use said movements of said frames and said arms cause a predetermined repetitive pattern to be formed on the surface of the material and the mold. 